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Otimização e melhoria contínua de processos industriais
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Advisor(s)
Abstract(s)
Atualmente, vive-se num Mundo onde o setor industrial está cada vez mais competitivo. Como
tal, existe uma necessidade constante das empresas procurarem maneiras de rentabilizar a sua
produção, procurando maximizar a performance de produção. Não só importante ter uma
produção rentável, como também garantir a sustentabilidade dos processos, sendo este cada
vez mais um fator significante e diferenciador nas empresas. A procura entre o equilíbrio de
uma produção rentável e sustentável obrigou a Indústria a revolucionar-se tanto a nível técnico
como metódico e moral. Através destas necessidades, foram desenvolvidas várias metodologias
e ferramentas que otimizam e melhoram um processo.
É no âmbito da otimização e melhoria contínua que se insere esta dissertação, onde foram
desenvolvidas e estudadas as ferramentas que fundamentam os processos de otimização e
melhoria contínua. O objetivo principal da tese é compreender estas ferramentas e saber
aplicá-las.
Primeiramente, foi feita uma revisão bibliográfica, onde através de vários estudos foi
desenvolvida uma base de conhecimentos teóricos. Paralelamente, foi definido um caso de
estudo que fosse relevante para o trabalho a ser desenvolvido, e escolheu-se como área de
intervenção uma linha de produção de garrafas de vidro e definiu-se implementar um ciclo
PDCA a este processo.
Assim sendo, tendo como base o conhecimento das filosofias Lean e Kaizen e ainda de
ferramentas práticas como VSM, 5S, 5W2H iniciou-se o plano de trabalho tendo sido feitas
várias visitas à fábrica, para compreender a linha de produção em causa. Fez-se um diagnóstico
de indicadores de performance e obtiveram-se os valores das taxas de peças defeituosas e
estabeleceu-se objetivos de melhoria.
De seguida, foram utilizadas as ferramentas diagrama de Ishikawa, 5W2H para perceber quais
seriam as causas que provocaram estes problemas e foram definidos planos de ação.
Foram então implementados os planos de ação corretivos e preventivos, evidenciando cada
responsável encarregue por o fazer.
Por constrangimento temporal e falta de permissões, os valores obtidos foram simulados
consoante os objetivos expectáveis definidos pela empresa X. A nível da taxa de defeitos teve
uma diminuição de 38,7%, O PTM médio teve um aumento de 1,7% e o tempo médio de ciclo
diminui 12,3% do tempo antes da intervenção. A nível de indicadores de performance (PpK)
verificaram-se melhorias significativas nas zonas do corpo, fundo e ponto de contacto superior
da garrafa. Foi feita uma análise dos resultados e uma reflexão sobre o seu significado e foi
desenvolvida uma proposta de formalização de ações preventivas e corretivas, que face ao
estudo desenvolvido, se acredita ser benéfico para a empresa qual X.
Nowadays, we live in a world where the industrial sector is increasingly competitive. As such, there is a constant need for companies to look for ways to make their production more profitable, seeking to maximize production performance. But not only is profitable production important, but ensuring sustainability has also become an increasingly significant and differentiating factor for companies. The search for a balance between profitable and sustainable production has forced the industry to revolutionize itself on a technical, methodical and moral level. As a result of these needs, various methodologies and tools have been developed to optimize and improve a process. This dissertation focuses on optimization and continuous improvement, where the tools that underpin optimization and continuous improvement processes have been developed and studied. The main aim of the thesis is to understand these tools and know how to apply them. Firstly, a literature review was carried out, where a theoretical knowledge base was developed through various studies. At the same time, a case study was defined that was relevant to the work to be carried out, and a glass bottle production line was chosen as the area of intervention, and it was decided to implement a PDCA cycle in this process. Therefore, based on knowledge of the Lean and Kaizen philosophies and practical tools such as VSM, 5s, among others, the work plan began with several visits to the factory to understand the production line in question. A diagnosis of performance indicators was made, and the values of defective parts rates were obtained and improvement objectives were set. Tools such as the Ishikawa diagram and the 5W2H were then used to understand the causes of these problems and action plans were defined. The corrective and preventive action plans were then implemented, with each person responsible for doing so highlighted. Due to time constraints and lack of permissions, the values obtained were simulated according to the expected objectives set by the company. The defect rate fell by 38.7%, the average PTM increased by 1.7% and the average cycle time fell by 12.3% compared to the time before the intervention. In terms of performance indicators (PpK), there were significant improvements in the areas of the body, bottom and top contact point of the bottle. The results were analysed and their significance reflected upon. A proposal was developed to formalize preventive and corrective actions, which, in view of the study carried out, are believed to be beneficial to the company.
Nowadays, we live in a world where the industrial sector is increasingly competitive. As such, there is a constant need for companies to look for ways to make their production more profitable, seeking to maximize production performance. But not only is profitable production important, but ensuring sustainability has also become an increasingly significant and differentiating factor for companies. The search for a balance between profitable and sustainable production has forced the industry to revolutionize itself on a technical, methodical and moral level. As a result of these needs, various methodologies and tools have been developed to optimize and improve a process. This dissertation focuses on optimization and continuous improvement, where the tools that underpin optimization and continuous improvement processes have been developed and studied. The main aim of the thesis is to understand these tools and know how to apply them. Firstly, a literature review was carried out, where a theoretical knowledge base was developed through various studies. At the same time, a case study was defined that was relevant to the work to be carried out, and a glass bottle production line was chosen as the area of intervention, and it was decided to implement a PDCA cycle in this process. Therefore, based on knowledge of the Lean and Kaizen philosophies and practical tools such as VSM, 5s, among others, the work plan began with several visits to the factory to understand the production line in question. A diagnosis of performance indicators was made, and the values of defective parts rates were obtained and improvement objectives were set. Tools such as the Ishikawa diagram and the 5W2H were then used to understand the causes of these problems and action plans were defined. The corrective and preventive action plans were then implemented, with each person responsible for doing so highlighted. Due to time constraints and lack of permissions, the values obtained were simulated according to the expected objectives set by the company. The defect rate fell by 38.7%, the average PTM increased by 1.7% and the average cycle time fell by 12.3% compared to the time before the intervention. In terms of performance indicators (PpK), there were significant improvements in the areas of the body, bottom and top contact point of the bottle. The results were analysed and their significance reflected upon. A proposal was developed to formalize preventive and corrective actions, which, in view of the study carried out, are believed to be beneficial to the company.
Description
Keywords
Lean Kaizen Ciclo PDCA Sustentabilidade Linha de produção Pack to melted Ratio (PTM) Ssutentabilidade Ciclo PDCA Linha de produção de garrafas de vidro